Airbag cover weakening patterns and related systems and methods

ABSTRACT

Airbag cushion covers and related methods. Some embodiments may comprise an airbag cover comprising a weakened pattern configured to facilitate separation of the cover during deployment of an airbag cushion. The weakened region may comprise a first tear seam comprising a first shape defined by a first line comprising at least one of regions of curvature and angled regions, and a second tear seam comprising a second shape defined by a second line comprising at least one of regions of curvature and angled regions. In some embodiments, the first shape may overlap and/or intersect with the second shape in a desired pattern to facilitate desired airbag deployment.

RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 15/090,517, filed on Apr. 4, 2016 and titled “AIRBAG COVERWEAKENING PATTERNS AND RELATED SYSTEMS AND METHODS,” which applicationis incorporated by reference herein in its entirety.

SUMMARY

Airbag cushions are often wrapped in covers, in some cases leathercovers, to hide the airbag cushion and provide a more aestheticallypleasing appearance to a vehicle's interior. Such covers are typicallyprovided with tear seams to facilitate exit of the airbag cushion fromthe cover during deployment. Such tear seams are often created using aneedle to perforate the leather/cover or a LASER to create a bore thougha substrate of the cover and a portion of the thickness of the top layerof the cover. These processes, however, are often very slow and timeconsuming. In addition, they can be difficult to precisely control andoften result in poor appearance of the cover (“read through”). Inaddition, the patterns provided by the prior art are often not ideal forcreating desired breakthrough/deployment characteristics.

The present inventors have therefore determined that it would bedesirable to provide apparatus, assemblies, and methods that overcomeone or more of the foregoing limitations and/or other limitations of theprior art. For example, the present inventors have determined that, byproviding, in some embodiments, airbag covers having particularweakening patterns configured to improve upon deployment characteristicsand/or improve the appearance of the cover, (such as by reducing readthrough), the above-referenced limitations, and/or other limitations ofthe prior art, may be avoided or improved upon.

In a more particular example of an embodiment of a cover for an airbagcushion, the cover may comprise a weakened region configured tofacilitate separation of the cover during deployment of an airbagcushion. The weakened region may comprise a first tear seam comprising afirst shape defined by a first line comprising at least one of regionsof curvature and angled regions; and a second tear seam comprising asecond shape defined by a second line comprising at least one of regionsof curvature and angled regions. In some embodiments, the first shapemay comprise, or may at least substantially comprise, a reflected imageof the second shape.

In some embodiments, the first shape may comprise a shifted, reflectedimage of the second shape. In other embodiments, the first shape maycomprise an unshifted, reflected image of the second shape such that thefirst shape has reflectional symmetry with respect to the second shape.In some such embodiments, the first shape may have reflectional symmetrywith respect to the second shape about a line of symmetry defined byanother tear seam. For example, in some embodiments, the cover mayfurther comprise a substrate. In some such embodiments, the substratemay comprise a substrate tear seam. In some such embodiments, the firstshape may have reflectional symmetry with respect to the second shapeabout a line of symmetry defined by the substrate tear seam.

In some embodiments, the first line and/or the second line may lack anysharp angles. For example, in some preferred embodiments, the firstshape may comprise a first sinusoidal wave pattern, and the second shapemay comprise a second sinusoidal wave pattern reflected with respect tothe first sinusoidal wave pattern. Thus, the weakened pattern maycomprise a dual sinusoidal shape.

In some embodiments, a radius of curvature of the first line may varywithin the first shape, and/or a radius of curvature of the second linemay vary within the second shape. In some embodiments, other features ofthe pattern may vary throughout the pattern, such as, for example, thedepth of the cut, the profile/amplitude of the pattern, the wavelengthof one or more tear seams (such as in patterns comprising sinusoids),etc. In some embodiments, a radius of curvature of the first line may beat least 0.5 mm along an entire length of the first line. Similarly, insome embodiments, a radius of curvature of the second line may also, oralternatively, be at least 0.5 mm along an entire length of the secondline.

In some embodiments, the cover may comprise a leather material. In somesuch embodiments, the weakened region may be formed in the leathermaterial. In some such embodiments, the weakened region may also beformed in another layer/portion of the cover. For example, in someembodiments, the cover may further comprise a substrate positionedadjacent to the leather material. In some such embodiments, the weakenedregion may be further formed in the substrate.

In a particular example of a method for manufacturing an airbag cushioncover according to some implementations, the method may compriseobtaining a first layer of an airbag cushion cover and forming a firstweakened pattern in the first layer such that the first weakened patternfacilitates separation of the first layer to allow for deployment of anairbag cushion therethrough. The first weakened pattern may comprise afirst shape. A second weakened pattern may also be formed in the firstlayer such that the second weakened pattern further facilitatesseparation of the first layer to allow for deployment of an airbagcushion therethrough. In some implementations, the second weakenedpattern may comprise a second shape comprising a reflected image of thefirst shape.

For example, the first shape may comprise a first sinusoidal wavepattern, and the second shape comprises a second sinusoidal wavepattern. In some implementations, the first sinusoidal wave pattern mayhave reflectional symmetry with respect to the second shape about a lineof symmetry.

Some implementations may further comprise coupling a second layer of theairbag cushion cover to the first layer and forming a tear seam in thesecond layer. In some such implementations, the tear seam may bepositioned in between the first weakened pattern and the second weakenedpattern. In some implementations, the line of symmetry may coincide, orat least substantially coincide, with the tear seam.

In another example of a method for manufacturing an airbag cushioncover, the method may comprise forming a first tear seam in a firstlayer of the airbag cushion cover and forming a second tear seam in asecond layer of the airbag cushion cover. One or both of the tear seamsmay be formed using a vibrating knife mechanism. In someimplementations, a computerized numerical control machine comprising avibratory knife may be used. In some implementations, the second tearseam (or in some implementations, all tear seams) may be formedcontinuously without withdrawal of the vibrating knife mechanism fromthe second layer. In some implementations, the second tear seam may beformed in a first shape comprising a varying radius of curvature.

In some implementations, a third tear seam may be formed in the secondlayer of the airbag cushion using the vibrating knife. In some suchimplementations, the third tear seam may be formed continuously withoutwithdrawal of the vibrating knife mechanism from the second layer. Insome such implementations, the third tear seam may be formed in a secondshape comprising a varying radius of curvature.

In some implementations, the varying radius of curvature of the firstshape and/or the second shape may be at least 0.5 mm along an entirelength of the respective second and/or third tear seams.

In some implementations, a first blade of the vibrating knife mechanismmay be used to form the second tear seam, and a second blade of thevibrating knife mechanism is used to form the third tear seam.Alternatively, both tear seams (and, in some implementations, additionaltear seams) may be formed by the same blade.

In some implementations, the vibrating knife mechanism may comprise acomputerized numerical control machine, which may be configured to allowfor controlling the varying radius of curvatures of the second and thirdtear seams during application/formation of the various tear seams.

The features, structures, steps, or characteristics disclosed herein inconnection with one embodiment may be combined in any suitable manner inone or more alternative embodiments and/or implementations.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the disclosure aredescribed, including various embodiments of the disclosure withreference to the figures, in which:

FIG. 1 depicts an airbag cover according to a preferred embodiment;

FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 1;

FIG. 3 depicts an alternative embodiment of an airbag cover;

FIG. 4 is a close-up view of a weakening pattern comprising twooverlapping tear seams for use in connection with some embodiments ofcovers for airbag cushions;

FIG. 5 is a close-up view of an alternative weakening pattern comprisingtwo overlapping tear seams for use in connection with some embodimentsof covers for airbag cushions;

FIG. 6 is a close-up view of yet another weakening pattern comprisingtwo overlapping tear seams for use in connection with some embodimentsof covers for airbag cushions; and

FIG. 7 is a close-up view of still another weakening pattern comprisingtwo overlapping tear seams for use in connection with some embodimentsof covers for airbag cushions.

DETAILED DESCRIPTION

A detailed description of apparatus, systems, and methods consistentwith various embodiments of the present disclosure is provided below.While several embodiments are described, it should be understood thatthe disclosure is not limited to any of the specific embodimentsdisclosed, but instead encompasses numerous alternatives, modifications,and equivalents. In addition, while numerous specific details are setforth in the following description in order to provide a thoroughunderstanding of the embodiments disclosed herein, some embodiments canbe practiced without some or all of these details. Moreover, for thepurpose of clarity, certain technical material that is known in therelated art has not been described in detail in order to avoidunnecessarily obscuring the disclosure.

Apparatus, methods, and systems are disclosed herein relating to airbagweakening patterns, which in some preferred embodiments andimplementations may be formed in airbag covers. More particularly, insome embodiments and implementations, various weakening patterns, suchas tear seams defining particular shapes, may be formed and used inconnection with airbag covers, such as leather-wrapped airbag covers,for example. Various implementations of methods for forming suchweakening patterns are also disclosed herein. For example, in certainpreferred implementations of such methods, a vibratory knife, such as acomputer numerical controlled vibratory knife, may be used to apply apreferred weakening pattern.

The embodiments of the disclosure may be best understood by reference tothe drawings, wherein like parts may be designated by like numerals. Itwill be readily understood that the components of the disclosedembodiments, as generally described and illustrated in the figuresherein, could be arranged and designed in a wide variety of differentconfigurations. Thus, the following detailed description of theembodiments of the apparatus and methods of the disclosure is notintended to limit the scope of the disclosure, as claimed, but is merelyrepresentative of possible embodiments of the disclosure. In addition,the steps of a method do not necessarily need to be executed in anyspecific order, or even sequentially, nor need the steps be executedonly once, unless otherwise specified. Additional details regardingcertain preferred embodiments and implementations will now be describedin greater detail with reference to the accompanying drawings.

FIG. 1 depicts an embodiment of an airbag cushion cover 100. Cover 100may comprise a cover for an airbag cushion and may comprise a singlelayer or, alternatively, may comprise multiple layers. For example, insome embodiments, cover 100 may comprise a top layer 110 which may, insome embodiments, be made up of leather or another decorative material.A substrate 150 or second layer may be positioned adjacent to top layer110. Substrate 150 may, but need not be, made up of a distinct materialwith respect to top layer 110. For example, in some embodiments,substrate 150 may comprise a thermoplastic material.

One or more weakened regions 120 may be positioned on/in cover 100,which may be configured to facilitate separation of cover 100 duringdeployment of an airbag cushion (not shown). Weakened region 120 may, insome embodiments, be made up of one or more tear seams, such as tearseams 122 and 124. In some embodiments, tear seams 122 and/or 124 mayextend through, either fully or partially, multiple layers of cover 100,such as through layers 110 and 150. Alternatively, tear seams 122 and/or124 may only extend through one layer of cover 100, such as top layer110. In some embodiments, tear seams 122 and/or 124 may only partiallyextend through layer 110, or another layer of cover 100.

In some embodiments, weakened region 120 comprises tear seams defining apreferred shape that may facilitate separation of one or more layers ofcover 100 in a desired manner. For example, in the embodiment depictedin FIG. 1, weakened region 120 may comprise a first tear seam 122comprising a first shape and a second tear seam 124 comprising a secondshape. These two shapes may be related to one another. For example, inthe depicted embodiment, first tear seam 122 may be defined by and/or atleast substantially track a first line defining a first shape and secondtear seam 124 may be defined be and/or at least substantially track asecond line defining a second shape that may be similar to the firstshape. Thus, in some such embodiments, the first shape comprises areflected image of the second shape. In some embodiments, the firstshape may comprise a shifted, reflected image of the second shape.However, in the depicted embodiment, the first shape is an unshifted,reflected image of the second shape.

More particularly, in the specific example depicted in FIG. 1, firsttear seam 122 defines a first sinusoidal wave pattern and second tearseam 124 defines a second sinusoidal wave pattern reflected with respectto the first sinusoidal wave pattern. In addition, in some embodiments,the two tear seams may collectively extend back and forth across anothertear seam or other weakened region that may be formed in another layerof the cover 100. For example, in the depicted embodiment, a linear tearseam 152 is formed within substrate 150 and tear seams 122 and 124extend back and forth across tear seam 152 along the pattern of weakenedregion 120. In some embodiments (including the embodiment of FIG. 1),tear seam 152 defines a line of symmetry such that the first shapedefined by tear seam 122 has reflectional symmetry with respect to thesecond shape defined by tear seam 124 about the line of symmetry definedby the tear seam 152 formed within substrate 150. Although, in theembodiment of FIG. 1, tear seam 152 is shown as only extending about aportion of weakened region 120 (namely, the top portion of weakenedregion 120), in other embodiments, tear seam 152 may extend about theentire pattern of weakened region, or may extend about a differentportion of weakened region 120 (such as the bottom portion of weakenedregion 120, for example).

Although certain preferred embodiments may comprise a line of symmetrydefined by a tear seam 152 formed within a substrate 150 or anotherportion of cover 100, it should be understood that, because theweakening patterns disclosed herein may improve certain desiredseparation/deployment characteristics, it may not be as important thatthe weakening pattern in the top layer 110 closely track a weakeningpattern in another layer, such as tear seam 152 in substrate 150. Thus,some embodiments are contemplated in which tear seam 152 need not definea line of symmetry, and/or in which tear seam 152 may only loosely trackweakening pattern 120 or be absent altogether.

The various weakening patterns disclosed herein may be particularlysuitable for preferred manufacturing methods involving use of vibratoryknifes, such as continuously-contacting vibratory, computer numericalcontrol knife systems. This may allow for relatively precise controlover dimensions in one or more directions (x, y, and z) from the “A”surface of the cover (i.e., the surface of the cover that a vehiclepassenger would typically see and/or be closest to while in thevehicle). For example, in some embodiments and implementations, use ofsuch cutting means may allow for maintaining desired radii of curvaturealong the weakened region in a very controlled manner. For example,because smaller radii of curvature tend to increase read through of thematerial, in some embodiments it may be desired to maintain a radius ofcurvature of one or more lines associated with the weakened region of atleast 0.5 mm along the entire length of each such line. In otherembodiments, such as, for example, those in which read through may notbe as big of a concern, it may be desirable to maintain smaller radii ofcurvature.

In some implementations of manufacturing methods, a double-sinusoidal orother desired pattern (such as connecting geometric shapes, for example)may be applied in which the blade remains in contact with the cover,such as the leather and/or top layer 110 during the entire applicationof the pattern, or at least during the application of one tear seam ofthe pattern. This may be useful for a number of different reasons, suchas increasing cutting speed and controlling movement of theleather/layer/cover. This may also allow for greater process flexibilityin alignment of the tear seams of the various layers of the cover, suchas tear seam 152 with tear seams 122/124. In addition, this may allowfor continuous radius changes to be made during the cutting process,which may allow for infinite, or near infinite, design variability onalignment of substrate tear seam to leather/top layer tear seam topromote propagation during airbag deployment.

FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 1. Asdepicted in this figure, weakened region 120, which is made up of tearseams 122 and 124, may only be applied to layer 110, whereas tear seam152 may only be applied to substrate 150. Thus, in certainimplementations of methods used to manufacture cover 100, a vibratoryknife or other cutting means may be used to apply the pattern ofweakened region 120 to layer 110 prior to coupling layer 110 tosubstrate 150. Alternatively, a vibratory knife or other cutting meansmay be applied after the two layers (or, in other embodiments, anynumber of layers) have been coupled together. Thus, in some suchembodiments and/or implementations, a weakened region comprising one ormore tear seams may be applied in which the tear seams fully extendthrough one or more layers of the cover, such as top layer 110, and onlypartially extend through one or more other layers of the cover, such assubstrate 150. In addition, although it may be preferable for certainapplications to create continuous tear seams, alternative embodimentsare contemplated in which one or more tear seams of one or more weakenedregions may comprise partial or broken tear seams.

In some embodiments and/or implementations, the cutting depth and/orlength of the various cuts may be varied in different parts of one ormore of the tear seams as desired to create different tear seamthickness and/or bridges. However, in certain embodiments, it may bepreferred that the cutting depth never extend all of the way through theleather or other material making up the top layer 110 of the cover 100,such that the appearance of the weakening pattern 120 is not visible onthe surface of the top layer 110 (the “A” surface).

FIG. 3 depicts an alternative embodiment of an airbag cushion cover 300.Like cover 100, cover 300 comprises a top layer 310 positioned on asubstrate 350. Again, a weakened region 320 is formed within layer 310.However, unlike weakened region 120, weakened region 320 comprises abottom portion 325 made up of a first pattern and a top portion 330 madeup of a second pattern. Bottom portion 325 of weakened region 320comprises tear seams 322 and 324 and top portion 330 of weakened region320 comprises tear seams 332 and 334.

Both top portion 330 and bottom portion 325 of weakened region 320comprise double-sinusoidal patterns made up of reflected sinusoidalshapes, similar to that of weakened region 120. However, the patterndefined by tear seams 322 and 324 is distinct from the pattern definedby tear seams 332 and 334. More particularly, the sinusoids associatedwith tear seams 322 and 324 are lengthened with respect to the sinusoidsassociated with tear seams 332 and 334. In other words, the “wavelength”of each sinusoid pattern is greater in the bottom portion 325 than inthe top portion 330.

As mentioned above, in certain preferred implementations of methods formanufacturing an airbag cover 300, use of vibratory knifes may providesufficient control to allow for making such changes on the fly. This mayallow for altering the weakening pattern as desired to fine tune thedesired airbag deployment characteristics. In some embodiments andimplementations, the various regions having differing tear seam orweakening pattern characteristics, such as top portion 330 and bottomportion 325 in FIG. 3, or at least a subset of such regions, may beconnected with one another such that a vibratory knife need not belifted during a transition from one such region to another such region.Thus, as can be seen in FIG. 3, the longer wavelengths of tear seams 322and 324 are smoothly coupled to the shorter wavelengths of tear seams332 and 334. In addition, the transition between bottom portion 325 andtop portion 330 represents one example of how a radius of curvature of aline or tear seam of a weakening pattern may vary within the pattern.

Of course a variety of alternative options, features, and/or steps arecontemplated. For example, in some embodiments and implementations, thepattern defined by tear seams 322 and 324 may be distinct from thepattern defined by tear seams 332 and 334 in other ways. For example,the “amplitude” of the pattern of one set of tear seams may be greaterthan the amplitude of another pattern. In other words, the distancebetween opposing peaks of the pattern may be greater in one region ofthe weakening pattern than in another. In embodiments in which a lineartear seam 352 is formed within substrate 350, the distance between tearseam 352 and either of the opposing peripheries of the weakening patternmay be greater along one portion of the pattern than another. Inimplementations utilizing a vibratory knife, and particularly a CNCvibratory knife, again, the transition between the various regions maybe made on the fly without lifting the knife from the cover 300. Asstill another alternative, in some embodiments and implementations, thedepth of the cut associated with one region of weakening pattern 320 maydiffer from another region. For example, if it is desired to have aparticular edge or portion of cover 300 open first, the depth of the cutof the weakening pattern 320 may be greatest in this region, and thenmay decrease along areas that are preferably separated later in thedeployment process.

FIG. 4 illustrates a close-up view of a weakening pattern comprisingtear seams 422 and 424 extending along a tear seam 452 that serves as aline of symmetry of tear seams 422 and 424. As previously mentioned, insome embodiments, tear seam 452 may be formed in one or more layers ofmaterial, such as a substrate, and the weakening pattern made up of tearseams 422 and 424 may be formed in one or more distinct layers ofmaterial making up an airbag cover, such as a leather decorative layerpositioned adjacent to the substrate, for example.

As shown in FIG. 4, tear seam 422 comprises a first sinusoidal shape andtear seam 424 comprises a second sinusoidal shape having reflectionalsymmetry with respect to tear seam 422. In the depicted embodiment, tearseam 452 serves as not only an independent tear seam, but also as a lineof symmetry for the above-referenced reflectional symmetry. In someimplementations, a single knife blade, such as preferably a vibratoryknife, may be used to form both tear seam 422 and 424. For example, insome implementations, a vibratory knife blade may form tear seam 422 inone direction and then reverse course to form tear seam 424 in theopposite direction. In some such implementations, this process may beperformed without lifting the knife blade from the material in whichtear seams 422 and 424 are being formed.

In other implementations, two or more separate blades may be used. Thus,for example, a first blade may be used to form tear seam 422 and asecond blade may be used to form tear seam 424, either simultaneously orsequentially. In some embodiments and implementations, at least one lineor tear seam of the weakening pattern may lack any sharp angles. In somesuch embodiments and implementations, all of the lines and/or tear seamsin the weakening pattern may lack any sharp angles. This may improve theability of the weakening pattern to avoid read through.

However, other embodiments are contemplated and, for some applications,may be viable, which comprise weakening patterns having sharp angles.For example, the weakening pattern depicted in FIG. 5 comprises a firsttear seam 522 and a second tear seam 524. Like the pattern depicted inFIG. 4, tear seam 522 has reflectional symmetry with respect to tearseam 524. However, unlike the pattern depicted in FIG. 4, both tearseams 522 and 524 comprise lines having sharp angles such that each ofthe respective tear seams defines a “zig-zag” pattern extending back andforth across tear seam 552, which, again, may be formed in a separatepiece of material of the cover, such as a substrate.

FIG. 6 depicts yet another example of a weakening pattern according tosome embodiments and implementations. The weakening pattern of FIG. 6again comprises two tear seams, namely, tear seam 622 and tear seam 624,that extend back and forth across an at least substantially linear tearseam 652. However, the weakening pattern of FIG. 6 differs from those ofFIGS. 4 and 5 in that one of the tear seams (tear seam 622) comprises atear seam defined by a series of spaced cuts rather than a continuouscut. The other tear seam of the pattern (tear seam 624) comprises acontinuous cut, as previously described. Of course, other embodimentsare contemplated in which both tear seams 622 and 624, or at least aportion of both tear seams, comprise intermittent or spaced cuts, ifdesired.

FIG. 7 depicts still another example of a weakening pattern according tosome embodiments and implementations. The weakening pattern of FIG. 7again comprises two tear seams, namely, tear seam 722 and tear seam 724,that extend back and forth across an at least substantially linear tearseam 752. However, the weakening pattern of FIG. 7 differs from theexamples of the previous drawings in a few respects. Most notably, theshape of tear seam 722 is a shifted, reflected image of the shape oftear seam 724 but does not have reflectional symmetry with respect tothe shape of tear seam 724. In addition, unlike the pattern of FIG. 6,in the pattern of FIG. 7 both tear seams 722 and 724 comprise continuouscuts. As mentioned above, in certain preferred embodiments, both of tearseams 722 and 724 comprise continuous cuts that only partially extendthrough a layer of a cover, such as layer 110 of cover 100.

The foregoing specification has been described with reference to variousembodiments and implementations. However, one of ordinary skill in theart will appreciate that various modifications and changes can be madewithout departing from the scope of the present disclosure. For example,various operational steps, as well as components for carrying outoperational steps, may be implemented in various ways depending upon theparticular application or in consideration of any number of costfunctions associated with the operation of the system. Accordingly, anyone or more of the steps may be deleted, modified, or combined withother steps. Further, this disclosure is to be regarded in anillustrative rather than a restrictive sense, and all such modificationsare intended to be included within the scope thereof. Likewise,benefits, other advantages, and solutions to problems have beendescribed above with regard to various embodiments. However, benefits,advantages, solutions to problems, and any element(s) that may cause anybenefit, advantage, or solution to occur or become more pronounced, arenot to be construed as a critical, a required, or an essential featureor element.

Those having skill in the art will appreciate that many changes may bemade to the details of the above-described embodiments without departingfrom the underlying principles of the invention. The scope of thepresent invention should, therefore, be determined only by the followingclaims.

The invention claimed is:
 1. A cover for an airbag cushion, comprising:a weakened region configured to facilitate separation of the coverduring deployment of an airbag cushion, wherein the weakened regioncomprises: a first tear seam comprising a first shape defined by a firstline comprising at least one of regions of curvature and angled regions;and a second tear seam comprising a second shape defined by a secondline comprising at least one of regions of curvature and angled regions,wherein the first shape at least substantially comprises a reflectedimage of the second shape, and wherein the first tear seam overlaps atleast in part with the second tear seam.
 2. The cover of claim 1,wherein the first shape comprises a shifted, reflected image of thesecond shape.
 3. The cover of claim 1, wherein the first shape comprisesan unshifted, reflected image of the second shape such that the firstshape has reflectional symmetry with respect to the second shape.
 4. Thecover of claim 3, wherein the cover further comprises a substrate,wherein the substrate comprises a substrate tear seam, and wherein thefirst shape has reflectional symmetry with respect to the second shapeabout a line of symmetry defined by the substrate tear seam.
 5. Thecover of claim 1, wherein the first line lacks any sharp angles, andwherein the second line lacks any sharp angles.
 6. The cover of claim 5,wherein the first shape comprises a first sinusoidal wave pattern, andwherein the second shape comprises a second sinusoidal wave patternreflected with respect to the first sinusoidal wave pattern.
 7. Thecover of claim 5, wherein a radius of curvature of the first line varieswithin the first shape, and wherein a radius of curvature of the secondline varies within the second shape.
 8. The cover of claim 5, wherein aradius of curvature of the first line is at least 0.5 mm along an entirelength of the first line, and wherein a radius of curvature of thesecond line is at least 0.5 mm along an entire length of the secondline.
 9. The cover of claim 1, wherein the cover comprises a leathermaterial, and wherein the weakened region is formed in the leathermaterial.
 10. The cover of claim 9, wherein the cover further comprisesa substrate positioned adjacent to the leather material.
 11. The coverof claim 10, wherein the weakened region is further formed in thesubstrate.
 12. The cover of claim 1, wherein the first tear seamintersects the second tear seam at a plurality of different locations.13. The cover of claim 1, wherein the first shape of the first tear seamcomprises an amplitude that is at least substantially identical to anamplitude of the second shape of the second tear seam.
 14. The cover ofclaim 13, wherein the first tear seam overlaps with the second tear seamsuch that the first shape comprises a center between opposing peaks thatat least substantially coincides with a center between opposing peaks ofthe second shape.
 15. The cover of claim 14, wherein the cover furthercomprises a substrate, wherein the substrate comprises a substrate tearseam, and wherein the center of the first shape and the center of thesecond shape at least substantially coincide with the substrate tearseam.
 16. A method for manufacturing an airbag cushion cover, the methodcomprising the steps of: obtaining a first layer of an airbag cushioncover; forming a first weakened pattern in the first layer such that thefirst weakened pattern facilitates separation of the first layer toallow for deployment of an airbag cushion therethrough, wherein thefirst weakened pattern comprises a first shape; and forming a secondweakened pattern in the first layer such that the second weakenedpattern further facilitates separation of the first layer to allow fordeployment of an airbag cushion therethrough, wherein the secondweakened pattern comprises a second shape, wherein the second shape isat least substantially identical to the first shape, and wherein thefirst shape intersects the second shape.
 17. The method of claim 16,wherein the first shape comprises a first sinusoidal wave pattern,wherein the second shape comprises a second sinusoidal wave pattern, andwherein the first sinusoidal wave pattern has reflectional symmetry withrespect to the second shape about a line of symmetry.
 18. The method ofclaim 17, further comprising the steps of: coupling a second layer ofthe airbag cushion cover to the first layer; and forming a tear seam inthe second layer, wherein the tear seam is positioned in between thefirst weakened pattern and the second weakened pattern.
 19. The methodof claim 18, wherein the line of symmetry coincides with the tear seam.20. A method for manufacturing an airbag cushion cover, the methodcomprising the steps of: forming a first tear seam in a first layer ofan airbag cushion cover such that the first tear seam facilitatesseparation of the first layer to allow for deployment of an airbagcushion therethrough; forming a second tear seam in the first layer suchthat the second tear seam further facilitates separation of the firstlayer to allow for deployment of an airbag cushion therethrough, whereinthe first tear seam overlaps with the second tear seam, and wherein thefirst tear seam defines a shape symmetrical with respect to a shapedefined by the second tear seam; coupling a second layer of the airbagcushion cover to the first layer; and forming a third tear seam in thesecond layer, wherein the third tear seam extends in between opposingends of a profile defined by the first tear seam and the second tearseam such that the first and second tear seams extend back and forthacross the third tear seam.